Numerical 3D Simulation of Cold Compaction and Springback for Particulate Reinforced Composites

Published

January 1, 2004

Author(s)

Li Ma, Tony Zahrah, Richard J. Fields

Abstract

Unlike conventional iron-based alloys, particular reinforced composites experience significant dimensional changes during springback and sintering. As a result, the final compact size is significantly different from the die geometry. This dimensional change presents one of the challenges to the wide usage of particulate reinforced composites in traditional press and sinter applications. Finite element modeling of the compaction and sintering of these composites can help predict the dimensional changes and enable tooling design for net shape molding without the need for multiple interactions on the die design. Constitutive models for powder compaction are used to simulatethe compaction of a gear made of aluminum reinforced composite. Numerical simulation is used to predict the relative density and stress distribution within the compact as well as the stress distribution within the tooling. The simulation tracks the relative density and stress distributions during compaction and ejection; The springback after ejection of the part from the die is also calculated. Measurements of the density distribution within a compact and springback show good agreement with the FEA simulation results.

Citation

Powder Metallurgy

Volume

47

Issue

No. 1

Pub Type

Journals

Keywords

finite element analysis, powder compaction, process modeling, springback

Citation

Ma, L. , Zahrah, T. and Fields, R. (2004), Numerical 3D Simulation of Cold Compaction and Springback for Particulate Reinforced Composites, Powder Metallurgy (Accessed November 7, 2025)